Fluid bed process



May 17, 1966 F. x. MAYER ETAL 3,251,678

FLUID BED PROCESS May 17, 1966 F. x. MAYER Em. 3,251,678 l FLUID BED PROCESS 2 Sheecs--Sheei'I 2 Filed Nov. 25, 1964 O u N- w. ON VNO N HQE Q L H oN .M one wmmm 5.5. ov f 525mm maomuh. f v om o S N d w m m r n.5 525mm 9.6mm?. f wwom 6mm mamwum.. /Q x E E L twzmnmmwu m=omwu+o1 o m u .fs s4 om?. I; 4 ze l S, Y, g 1 ./N i 8. i y f :ww: www. wmv :wm: www :mw: M Mmuuwmmw. zmmmom. zo xmms. OON-\.mm xmms. oON-\m mh mojom United States Patent O 3,251,678 FLUID BED IRCESS Francis Xavier Mayer, .lesse Matteau Carr, Jr., and .lohn Frederick Moser, Jr., all of Baton Rouge, La., assignors to Esso Research and Engineering Company, a corporation of Delaware Filed Nov. 2S, 1964, Ser. No. 412,241

Claims. (Cl. 7S-26)v I `This is a continuation-in-part of U.S. application S.N. 274,234 iiled April 19, 1963, now abandoned.

This invention relates to a method for the production of sponge iron in fluidized bed reactions wherein oxidic iron `ores are directly contacted with reducing gases. In particular, it relates to an improved method wherein iluidized oxidic iron ores are metallized by direct countercurrent Contact with hydrogen, carbon monoxide, or mixtures of these and other gases.

It has been long known to contact particulate solids with ascending gases to fluidize the solids and form lluidized beds for carrying out chemical reactions. In a fluidized bed the velocity of the upwardly owing gas is correlated with the particle size and density of the solids to suspend the latter in a -dense turbulent state simulating a boiling liquid. The solids particles undergo extensive vertical and horizontal motion but nonetheless assume a pseudo liquid level. Such processes, inter alia, assure lbetter heat transfer and improve process efficiency. In present commercial processes, iiuidized beds are provided wherein the solids particles are of Esubstantially uniform particle size distribution. In such reactions, relatively little change of particle size takes place during the operation and, to the extent that nes are produced, these are removed from the process. Such processes generally have operated quite successfully.

'The art also discloses fiuidized processes relating specifically to the production of sponge iron by reduction of oxidic iron ores, i.e., ores consisting essentially of oxides of iron. In such processes, particulate oxidic ores at elevated temperatures are also fluidized by contact with ascending gases and reduced. The process may provide a single iiuidized bed or a plurality of iluidized beds, vand in the latter case the beds are staged as separate reduction zones. During the reduction, particularly when the degree of metallization becomes high, the particles undergo changes in size and shape, including some growth by agglomeration of small particles into larger particles, but primarily there is a net decrease in particle size due to decrepitation. The very small paritcles or iines produced can only accumulate to a limited extent since they are gradually lost in the effluent evolved from the process.

In the most advanced of the lluidize'd iron ore reduction processes, though to present knowledge none has been commercialized, the reduction zones are staged, since staging offers certain advantages. In such processes the particulate oxidic iron ore being treated is owed downwardly from one zone to the next and contacted in the separate zones by an ascending gas, or gases. In each succeeding zone, the ore is reduced to a lower state of oxidation. Thus, in a first zone, or zones, the oxides are reduced from the ferrie state to magnetic oxide of iron. In a succeeding zone, or zones, the magnetic oxide of iron is reduced to ferrous oxide. In yet another succeeding zone, or zones, the ferrous oxide is reduced to metallic iron. The different stages are generally operated at diierent elevated temperatures, and certain advantages are offered wherein the temperature is maintained at a higher level in the zones of highest metallization. Fluidized iron ore reduction processes, as contrasted with fiuidized processes inrgeneral, offer unique and diicult problems, particularly where the process is staged.

ICC

In an iron ore reduction process, especially a staged process, it is, inter alia, extremely didicult to maintain proper iiuidization of the ore. This difficulty arises as a result of a phenomenon known as bogging. It is characterized by a loss of iiuidization in the tiuidized beds and appears to be caused by a stickiness occurring upon the surfaces of the individual iron ore solids particles. The stickiness tends to produce adherence between individual particles and hence produces agglomeration.

While applicants have no desire to be bound by any theory on mechanism, it is believed that the individual particle surfaces of the ore become covered, wholly or partially, with crystalline forms of iron. These crystalline forms, microscopic in character, take on the appearance of nodules or whiskers extending outwardly from the surfaces of the indivi-dual particles. Such projections produce locations for. attachment upon contact one particle with another .so that the individual iron ore particles cling together to produce aggregates or agglomerates. The formation of these sites becomes more pronounced as reduction proceeds. This phenomenon is much like Isintering of the particles in its eiect but it occurs at an even lower temperature, i.e., below about l800 F. Sintering, however, is caused by an actual melting of the reduced iron upon the surfaces of the particles, this causing the individual particles to stick or weld together upon contact one with another to produce agglomeration.

Begging, or the tendency of the process to bog, produces a host of problems and militates against attempts to provide a more erlicient fluidized iron ore reduction process. Providing a staging of the reduction zones or increased temperatures would thus normally be considered Very desirable inasmuch as process eiiiciency should be improved. This is only true to a degree, however, because increasing temperature and increased metallization increases the tendency of the process toward bogging. The problem is particularly acute in a ferrous reduction zone, or zones, especially in the advanced metallization stages of reduction wherein the age distribution of the particles is narrow, i.e., where the sum total of the particles have remained within the zone for va short period of time. Thus, where the age distribution of -the particles is narrow, there are relatively few particles of higher oxidation to dilute the surface eifects and hence the number of particles possessing relatively high nodular growths are in more intimate contact. The problem becomes particularly acute in the ferrous reduction stages, particularly as the degree of metallization increases. Also, the operation of such process is especially troublesome when hydrogen, or mixtures of gases containing hydrogen, is employed as a reducing gas.

The bogging tendency in reducing fluidized iron ores also appears to militate against other normally acceptable prior art practices which relate .to the processing of fluidized solids systems generally. For example, it would normally be expected from present commercial uidized solids process that solids particles of a high uniformity of small particle sizes would `offer advantages in processing. It may be expected that this technique would improve process eiiiciency. Thus, one would expect chemical reaction rate to increase and higher reduction to be obtained. In practice, however, it is found that a ne, uniform particle size distribution aggravates the tendency toward bogging. On the other hand, it might also be expected that certain advantages could be attained in the actual grinding operation if the ore approached a normal random size distribution. This is not so, however; instead, there is an even more pronounced tendency toward bogging than occurs in the case of providing a fine, uniform particle size distribution.

These problems present a dilemma for it would appear that essentially every desirable condition which may be expected to facilitate or improve the process intensifies the problem of bogging.

The present invention, despite all these and other difficulties, however, has for its primary objective a-solution to the problem of bogging. In particular, its prime object is to provide the art with a simplified, new, and improved fluidized iron ore reduction process wherein bogging is suppressed and, at certain conditions of operation, virtually eliminated so that more elevated process temperatures can be used and operation conducted more effectively for longer periods. An object also is to provide such process wherein oxidic iron ores are successively treated with a reducing gas, or gases, in a series of staged reaction zones to reduce the iron oxides to lower stages of oxidation, and to metallic iron. An even more particular object is to provide a process employing a series of staged reaction zones at different elevated temperatures wherein hydrogen gas, or a gas containing significant portions of hydrogen, can be used as the reducing gas, while the tendenc'y toward bogging is suppressed, or eliminated. A yet further particular object is to provide a process wherein bogging within a ferrous reduction zone, or zones, is inhibited, or eliminated, even when hydrogen, or hydrogen containing gases, is used in the reduction.

Surprisingly, it has been discovered that these and other objects can be achieved in accordance with the present invention which contemplates maintaining within a uidized iron ore reduction bed, or zone, from about to about 60 weight percent of a lines concentration ranging from about 1/10 to about 1/3, and preferably from about 1/5 to about 1A, of the average mean particle size of the total of the particles constituting the fluidized bed. If less than suchrange of concentration of nes is maintained within the bed, in relation to the average mean particle size, the bed becomes turbulent and efficiency is drastically reduced. Operation becomes impractical. On the other hand, if substantially higher uniformity of particle sizes or a greater' concentration of fines are pro- Vides, the bed defluidizes or bogs.

The particles generally range in size from about two microns to about 5000 microns, and lines denotes particles which will pass through a standard 325 mesh Tyler screen. A preferred particle size distribution of iron oxides solids particles is one ranging from about 46-99 microns (4 mesh) to about 2 microns, and the fines within such distribution, preferably, range from about 2` microns to about 44 microns (325l mesh). Preferably, the average mean particle size of .the ore employed should range between about 35 and about -100l mesh, and more preferably from about 48 to about 65 mesh.

Concentrations of fines ranging from about 5 to about weight percent of the total distribution of particle sizes is particularly effective in processes wherein the fluidized iron ore reduction process utilizes a single reduction zone or no more than a duality of stages. Up to about percent lines have been employed successfuly under certain ideal conditions, however, where the reaction was not staged; and, up to percent nes have been used in certain instances where two stages were provided, and begging did not occur. Where the number of stages does not exceed two, however, significantly greater concentrations of lines produce begging, and bogging can occur when greater than a 20 percent concentration of fines is employed.

Where three or more reduction stages are employed, it is preferable to increase the nes concentration to the process, and it can be increased up to as high as about 60 weight percent and the process operated satisfactorily. Where not more than three stages are employed, however, it is preferable not to exceed percent fines. Concentrations ranging from about 10` to about 35 weight percent provide optimum results when three or more reduction stages are employed. This particular and higher level of lines, i.e., 10-35 percent, is especially effective in increasing Igas efficiency and gas utilization when the ferrous reduction zone, or zones, is operated at very high metallizations, at narrow ranges of particle age distribution, and at high temperatures. Thus, bogging does not occur in a ferrous reduction zone even when metallization (percent metallic iron in the liuidized ore) is on the order of to 90 percent, and higher, and even when the temperatures range as great as, and even greater than, about 1200" F. This vis so even when hydrogen gas is employed as a major portion of the reducing gas. In fact, when hydrogen is not a major portion of the reducing gas, temperatures can range as high as about 1500" F. without significant loss of 'gas emciency and gas utilization.

` The average mean particle size is deiined as the size of a particle at which point there is 50 weight percent of solids particles of lesser size and 50 weight percent of solids of greater particle size. Moreover, this relationship holds whether there is a wide size distribution or a narrow size distribution of the particles. A relatively narrow size distribution-wiz., from about 4 to about 400 mesh-however, is greatly preferred. This size distribution produces optimum gas utilization and maximizes reduction, and the process is operated without bogging. Within the range ofl particle sizes a distribution is preferable which can be plotted logarithmically as a straight line when size in microns is plotted against cumulative weight percent. This curve can, however, be skewed to some extent at either end of the plotted curve.

In the reduction of oxidic iron ores in accordance with the best practice of this invention, the superficial velocity of the fluidizing gases is provided such that a substantial portion of the lines normally generated by decrepitation is entrained and removed from the rprocess to prevent overaccumulation. These lines are recycled to the process in sufficient quantity to maintain the desirable range of critical concentrations and proper particle size distribution. Fines are preferably removed from the top of the bed where, due to elutriation, the fines are in higher concentration. The actual concentration of fines in the fluid bed at `any time can be ascertained and readily controlled by pressure or density measurements of the uidized bed at different levels in the bed.

The apparent density of a properly iluidized bed of partiallyreduced iron ores generally ranges between about 50 and 130 lbs./ft.3, depending upon the gas velocity, which can range from about 1 to about 5 feet per second, but preferably from about 2 to about 4 feet per second. Pursuant to this invention, optimum gas solids contacting, metallization, and gas utilization can be obtained under particular iiuidizing gas reaction condi-tions. Further, minimum residence times are provided and there is less equipment expense.

It is hypothesized that the duality or critical relationship between these critical ranges of concentrations of nes and the ratio of fines to absolute particle size distribution provides lthese outstanding benefits due to a lessening of contact surfaces between the individual ore particles. Thus, increase in temperature increases reaction rate, but it also increases crystalline iron or nodule formation on the particle surfaces. This increases the number of possible points of contact between the nodules of the individual particles and therefore intensifies the tendency of the ore to bog. As metallization increases, an increased tendency for the ore to bog occurs because of the greater concentration and proximity of particles with active sites for possible attachment lone to another. Very high uniformity of particle size, or too many fines, also increases the bogging tendency because of an increased surface effect which increases the points of possible contact between the nodules of the particles. At the other extremity, however, too great a size difference between particles even more severely increases the tendency toward bogginlg. This is believed so because the smaller particles actually fill and pack the voids between larger particles resulting in an actual increase of surface contact between particles. On the one hand, then, too much neness is undesirable, or, on the other hand, too much coarseness is also undesirable. Only where there is an optimum balance between nes and the coarser particles, as in the present invention, is there a tendency for the small particles to effectively lubricate the movement of the larger and coarser particles. Thus, some particle size disruption is necessary, essential, and indeed critical for eliminating the tendency for the sticking together of the particles and for the improvement of gas-solids contact, in accordance with this invention.

The invention will be better understood and is exemplied by reference to the attached drawings and to the detailed description which makes reference to these drawings.

In the figures:

FIGURE l is a schematic representation of one suitable form of physical equipment and involves a two-step, direct reduction method showing the withdrawal and separation of lines from an entrained solids off-gas and also the recycle of a portion of the fines to a reaction zone.

FIGURE 2 graphically illustrates the effect of lines concentration kon uidization by showing the effect on ferrous reducer inlet pressure, the pressure across ferrous reducer grid, and the apparent density of the solids in the ferrous reduced portion of a reactor. This figure is discussed in relationship with the working examples.

Referring to FIGURE l is shown a series of two reaction vessels 1, 2 which contain beds of particulate iron ore 3, 5 fluidized by contact with upwardly owing reducing gas. Iron oxides consisting essentially of ferrie oxide are continuously introduced into bed 3 of primary reactor 1 through line 7. In the reactor 1 the ore is reduced to an intermediate product which, though it `consists substantially of ferrous oxide, also contains minor amounts of higher oxides and some metallic iron.

Ascending gascurrents maintain beds 3, 5 in fluidized state. Reducing gas is introduced into reactor 1 through line 13 via a suitable gas distributor (not shown) wherein it fluidizes the solids of bed 3. The liuidizing gases in contact with the solids of bed 3 entrain the ner particles and carry these into chamber 4 where they are withdrawn through line 14 into cyclone separator 15. The entrained solids are therein separated from the gases and all or a portion thereof return through line 17 either to bed 3 or through line 18 and valve 19 to be removed from the reaction zone or fed to reactor 5 via line 20 and valve 22. Alternately, the fines can be fed through line 20 and valve 22 to line 23 wherein they are admixed with product withdrawn through line 9 and removed from the reactor.

The fines that are not recycled to the reactor can be subsequently treated, if necessary, in a separate Zone to obtain the desired degree of reduction. Thus, it is generally advantageous to separately treat these fines rather than discard them, for the concentration of fines within the uidized bed cannot be allowed to build up to an undesirably high level.

The partially reduced iron ore from bed 3 overflows into downcomer 8 and is introduced into bed 5 of reaction Zone 2. The lever of the uppermost extension of downcomer 8 thus determines the level of fluid bed 3. Reducing gas from a suitable source is introduced through line via a suitable gas distributor (not shown) wherein the gas fluidizes the solid particles and maintains a uid bed 5 in this zone. The gases flow continuously upwardly and countercurrently to the flow of iron oxide. The necessary heat to carry out the endothermic reduction reactions can be supplied by conventional means, c g., by preheating the iron oxide or reducing gas, or both.

In reactor 2, the ferrous oxide is reduced generally to 85 to 95 percent iron, which is then withdrawn through line 9 as product. The uidized gases in bed S entrains finely divided particles, carrying these into chamber 6 wherein they are withdrawn through line 11 and fed to cyclone separator 12. In the separator 12 the fines are separated from the gas and returned to bed 5 through lines 21 and 20. The fines may even be admixed with fines already in line 20 and then returned to bed 5. If the'concentration of nes present in bed 5 becomes too large, the lines can be diverted through line 23 and removed from the reaction zone with the product in line 9.

In the operation of such process, in accordance with this invention, certain conditions are generally employed. Thus, in primary reactor 1 the oxides are reduced substantially to ferrous oxide at temperatures ranging generally from about 1000 F. to about l600 F., and preferably from about 1200 F. to about l500 F. Generally, a pressure of from about 5 to about 150 p.s.i.g. is utilized and the average residence time of the uidized solids is from about 6 to about 24 hours, but preferably from about 5 to about l0 hours. The superficial velocity of the gases ranges preferably from about 2 to about 4 feet per second.

The temperature of reactor 2 is generally maintained at least about lO0O F., and preferably from about 1200 to about l600 F., or at a temperature insucient to cause defluidization under the prevailing conditions. The pressure is maintained at from about 5 to about 160 p.s.i.g. The conditions of reduction, i.e., temperature, degree of metallizatiomnes concentration, and velocity of fluidizing gas of reactor 2, are much more critical herein than in reactor 1, since as the degree of metallization increases, the tendency for fines present in the luidized bed to agglomerate and bog and defluidize the bed is far greater.

The tiuidizing gas velocity of bed 5 is therefore preferably maintained at from about 2.5 to about 4.0 ft./sec. and there is provided an average residence time for the solids of bed 5 of from about 6 to about 24 hours. upper temperature limit in this zone is particularly critical and is governed by the maximum temperature that does not cause particles to sinter or otherwise agglomerate. The sticking temperature varies with process conditions and with the type of ore, but under a speciiied set of process conditions the temperature can be elevated with the use of fines concentrations in relation to a given particle size distribution in accordance with this invention.

The lines concentration in beds 3, 5 is preferably maintained by density measurements in the beds and the fines recycle is adjusted to obtain the desirable bed density and lines concentration. A suitable bed density for carrying out the reduction reaction in bed 5 ranges generally from about 70 to 140 lbs./ft.3, and preferably from about 80 to about 110 lbs./ft.3. The fines concentration in bed 5 is maintained at a percentage of about 5 to about 20 percent, and preferably at from about 10 to about 15 percent. A suitable bed density for the optimum fines concentration vis from about -100 lbs./ft.3. By adjusting the percentage of fines recycled to beds 3, 5, the optimum gassolids contacting can be obtained in both beds easily, etliciently and continuously, thereby obtaining optimum reduction of iron oxides to metallic iron for a prolonged period of operation.

It is also feasible, and in fact preferable, to provide greater number of stages of reduction along with increases in nes concentration. For example, one or a plurality of ferric reduction Zones or one or a plurality of ferrous reduction zones, or both, can be employed. With the increasing number of stages, lines concentrations should preferably be increased. Conditions of temperature, pressure, degree of uidization and the like within the different stages can be the same or different. In essentially all circumstances, the degree of reduction from one stage to the next is increased.

The invention will be better understood by reference to the following nonlimiting examples, demonstrating the more salient features of the invention.

To more vividly demonstrate the benets of the present invention, the initial examples will, in fact, be specifically The directed to the use of critical quantities and particular particle size distributions of lines employed Within the ferrous reduction zone of the two-stage reduction process described, the ferrous reduction zone being that wherein begging is the most severe. Moreover, gas containing major quantities of hydrogen is employed, this reducing gas tending to produce bogging far more rapidly than a synthesis gas consisting primarily of carbon monoxide Without hydrogen.

Example I Reducing gas consisting essentially of 40 volume percent nitrogen and 60 Volume percent of 90 percent purity hydrogen is directly and countercurrently contacted with a' partially reduced iron ore consisting essentially of ferrous oxide. The reduction is carried out at a temperature of 1200 F. and a pressure of 20 p.s.i.a. The feed to the reducing operation is ground in an impact mill to provide the particle size distribution shown below:

Particle size, mesh: Percent 4 200 13 325 12 Pan (-Finer than 325 Mesh) 10 The range of particle sizes of the feed is thus shown to be 4 mesh to 325 mesh, or finer. The average means particle size of the particles in the bed is about 48-65 mesh. A bed having a diameter 1A; the bed height is maintained by continuously feeding the iron ore to the bed and continuously withdrawing 85 percent metallized iron. The bed is fluidized by contact with reducing gas introduced therein at a superficial linear gas velocity of 3.25 ft./sec. Five hundred parts of lines are continuously withdrawn from the bed with the entrained gases and 410 par-ts of the -fines are returned, -this maintaining a iines concentration of from about 12414 percent of particle size less than 325 mesh. The reaction proceeds smoothly and efficiently showing no tendency to bog.

When the foregoing example is repeated in exact detail, however, except that the `fines concentration is reduced lto about 4 percent lines, the bed becomes poorly fiuidized, turbulent and rough. Very inefficient iuid solids contacting takes place.

When the example is again repeated in precise detail except the fines concentration is increased to slightly above 20 percent, vthe bed becomes unstable and eflicient gas solids contacting rapidly deteriorates. The process then becomes entirely inoperative due to begging.

Examples 2-4 EFFECT OF FINES CONCENTRATION Run Number 2 3 4 5 6 Per Cent Solids, 325 Mesh or Less 1 5 9 18 24 Percent Metallization (1) 67. 5 80.0 96. 5 Bogged AGas Utilization 41. 2 55.0 59. 4 Bagged 1 Violent turbulent bed; though some reduction occurs, the process is entirely impractical.

Examples 5-8 The following tabulates yet another series of runs under conditions similar to the foregoing. In these instances, however. the te-mperature is considerably elevated-i.e.,

to l390 F.-this being feasible because of a lessening of the amount of hydrogen contained in the reducing gas. Thus, the uidizing gas contains 4() percent hydrogen (9() percent purity), 20 percent carbon monoxide, and 40 percent nitrogen. The results of these runs are set forth as examples (Runs 9-12) and demonstrations (Runs 7, 8, and 13) in the table below. It will be observed that gas utilization, i.e., percent of reducing gases actually utilized in reducing the oxides, is considerably improved because of the ability to operate at higher temperature without bugging. Also, a range of from about .9-12 percent fines appears about optimum.

EFFECT OF FINES CONCENTRATION Run Number 7 8 9 10 l1 12 13 Per Cent Solids thru 325 Mes 1 3 5 9 9-12 18 24 Percent Metallization. (l) (l) 80 90 91. 5 Bogged Gas Utilization, percent- 40 53 62 70| 75 Bogged IAt these conditions, violent, turbulent motion of the solids occurs, and the process becomes inoperative.

The following example and pertinent demonstrations show the use of an even greater concentration of fines, in accordance with this invention. Again the results are directed to elimination of bogging within a ferrous reduction zone. In these illustrations, a four-stage fluidized iron ore reduction process is employed.

Example 9 A large quantity of raw ore is pulverized in a ball mill, and divided, into like portions. The sieve analysis of the ore is las follows:

(Percent fines, 20)

A portion of the ore is charged into a fluidized iron ore reactor providing a series of four-stage fluidized zones, two ferrie reduction zones, 'and two ferrous reduction zones. The ore is fluidized by an ascending gas initially 40 percent hydrogen, 20 percent carbon monoxide, and 40 percent nitrogen. The gas flows from a zone containing an iron ore at `a lower level of oxidation to a zone wherein the ore is at the next higher level of oxidation, i.e., from the bottom to the top of the reactor. In the top ferrie zone the gas is burned with air to provide heat for the reaction.

The ferrous reduction stages, wherein ferrous oxides are reduced to metallic iron, are operated at 1400 F. The ferrous oxide is reduced, in the first stage, `to provide 27 percent metallization and, in the linal stage, to produce 93 percent metallization.

From each ferrous reduction zone is withdrawn lines and a suiiicient portion thereof is recycled to provide 39 percent and 26 percent lines in the first and final stages,

' respectively. Pursuant to such operati-on, gas utilization is on the order of percent and there is no tendency towards begging.

In sharp contrast, however, when the fines within the ferrous reduction zones are increased to slightly above 60 percent, the smooth operation is interrupted Within only a few minutes. This interruption is characterized -by an apparent loss of uidization in the ferrous reduction zones, this being indicated by an apparent loss of density land level within the iluidized beds. Also, there 1s bypassing of the fluidizing gas and spreading of ternseverely bogged within moments.

In FIGURE 2 of the drawings is shown the relationship between the density of the iluidized beds and the percent nes contained in the beds. As nes decrease below -a desired level, the density of a bed, as manifested by measurement of pressure, becomes highly variable, this resulting in poor operation, poor gas utilization, and loss of operating eiciency.

'Eiciency of fluidization is thus shown by reference to the graph designated A and B in the drawings. It is seen that at low lines concentration the variation in differential pressure `drop across the fluid bed and the ferrous reducer grid is about l and 0.78 p.s.i.g., respectively, while a fines concentration of about 4 percent and greater is provided. Then, unexpectedly, these differential pressures increased to labout 4 and 2 p.s.i.g., respectively, when nes concentration is reduced below about 4.0

percent.

Data designated as C of the drawing show the -ferrous reducer density of the fluid bed undergoing reduction. At

about 1.4 percent lines concentration, the apparent density of the ferrous bed varies violently at the points of measurement between about O and '200 lbs./cu. ft. Such rapid variations in density occurring in the bed indicate very ineiiicient iiuids solids gas lcontacting and a violent, turbulent bed. This unfavorable condition continues up through a concentration of about 4 percent rines, after which concentration is exceeded, the bed suddenly quiets down and eicient fluidization is obtained. In this instance the density averages out between SOvto 90 lbs/ft.3 and about 120 to 125 lbs./ft.3, the two readings being taken at two diierent levels in the bed. At the measuring points, the

density varies only by about 5 lbs/cu. ft.v in the bottom of y the bed and in the top of the bed as distinguished between violent density variations when less than 4 percent nes were present.

These data clearly show the criticality of the percentage of rines present in the fluid -bed in obtaining efficient iiuid solids gas contacting. TheV data also clearly show that even though a uidized bed condition may be provided, an e'licient solids gas contacting is not necessarily obtained.

The technique of the present invention consists primarily in maintaining the nes concentration in a bed of particles undergoing a ilui-dized reac-tion within critical limits whereby eilicient fluidization, eicient gas solids contacting, gas utilization, and optimum reaction conditions can be obtained. This technique can be used in contacting any solids with any gases and has particular application -to the reduction of iron ore. The technique could be used advantageously with any fluid solids contacting process and has particular application where fluid bed reaction zone processes are carried out and decrepitation of the coarse particles results in a net fines increase. Also, by measuring the density in the iluid bed, the amount of fines present in the bed can be readily ascertained and the amount of fines required to be recycled to the bed to maintain optimum i'luidization conditions can be determined and the average iines concentration in the fluidized bed can be carefully controlled within the described limits. This technique can be used where particles of either narrow or wide size distribution are fluidized.

The critical concentration of nes used in accordance with the present invention and a technique for controlling the fines concentration is applicable to various metal oxides reduction processes which can be reduced in a Huid bed reaction zone. Although iron ore has been speciically described as the metal oxide being reduced, the invention is also applicable to the reduction of other metal oxides, metal suldes, etc.

Other modiiications and variations of the invention may be made without departing from the spirit and scope of the invention, and therefore only such limitations should be imposed as are indicated in the appended claims.

Having described the invention, what is claimed is:

1. In a process wherein iron oxides solids particles the average mean particle size of which ranges between about 35 and about 100 mesh are fluidized in a bed by contact of ,the particles with upwardly flowing gases and reduced, the improvement comprising controlling the particle size distribution and concentration of fines solids particles by withdrawing from the. 'bed iines ranging in particle size from about 1/3 to 1A() the average mean particle size of the total solids constituting the bed and recycling a sul cient amount of these fines to the bed to maintain the concentration thereof within the bed at from about 5-60 weight percent to provide greater efliciency of con-tact between gases and solids. Y

' 2. The process of claim l wherein the withdrawn nes range in size from about.% to 1/5 of the mean of the total iluidized solids particles constituting the bed.

3. In a process wherein iron oxides solids particles are suspended as a fluidized bed by contact of the particles with upwardly liowing reducing gases consisting essentially of hydrogen and from 0 to about 40 percent lcarbon monoxide, based on total gases, at a temperature ranging from about l000-l600 F., the improvement comprising controlling -the particle size distribution and -concentration of the nes solids particles within sizes ranging from about 4 mesh to about minus 325 mesh while withdrawing par ticles of less than minus 325 mesh from said iiuidized .bed and recycling a suiicient amount of these fines particles to the i'luidized bed to maintain the concentration thereof in said bed in quantity ranging from about 4-20 weight percent so asV to provide greater efficiency of contact between gases and solids.

4. The process of claim 3 wherein said reducing gas consist essentially of hydrogen, the temperature ranges from about l000-l200 F., and wherein the nes recycled to the bed are maintained in concentration ranging from labout 9-12 weight percent.

5'. The processof claim 3 wherein said reduction is conducted'at a temperature ranging from about 1200-1600 F., the reducing gas consi-sts essentially of a mixture of hydrogen and carbon monoxide in ratio of hydrogen to carbon monoxide ranging from about 1 to about 0.5, and wherein the fines recycled to the bed are maintained in lconcentration ranging from about 9-18 weight percent.

y6. In an iron ore yreduction process wherein iron oxides solids particles consisting essentially of `ferrous oxide and metallic iron particles suspended as a uidized bed by Contact with upwardly flowing reducing gases consisting essentially of hydrogen from about O to 40 percent carbon monoxide, based on total gases, at temperatures ranging from about 1000 to about l600 F., the improvement comprising controlling the particle size distribution and concentration of nes solids particles by maintaining said solids particles in random size distribution ranging from about 4 mesh to about minus 325 mesh and withdrawing particles ranging in size from about 1/a to 1A@ of the mean l particle size of the total particles constituting said fluidized -bed and recycling a -suiiicient Iamount thereof to the bed to maintain the concentration of these particulate fines in the bed in quantity ranging from about 4-20 weight percent so as to provide greater efficiency of contact between gas and solids.

7. The process of claim 6 wherein the mean particle size of the bed ranges from about 35 to 60 mesh.

8. The process of claim 6 wherein the fines removed are of size less than about minus 325 mesh.

9. The process of claimv 6 wherein the reducing gas consists essentially of hydrogen, the temperature ranges from about 10001200 F., and the concentration of the lines maintained within the fluidized bed ranges from about 9-12 weight percent.

10. The process of claim 6 wherein the reducing gas consists essentially of a mixture of hydrogen and `carbon monoxide, the ratio of hydrogen to carbon monoxide 1 1' ranges from about 1 Ito about 0.5, the temperature ranges from about 1200-1600 F., :and wherein the concentration of solids particles maintained within the bed ranges from about 9-18 weight percent.

11. In a reaction stage of -a process wherein ferrous oxides solids particles -the average mean particle size of which ranges between about 35 and :about 100 mesh are uidized in a bed and metallized lby contact of the particles with upwardly owing gases and reduced, the improvement comprising maintaining the particle size distribution and concentration of lthe fines solids particles by withdrawing from the bed fines ranging in particle size from about 1/10 to about l the averagey mean particle size of the total solids constituting the -ferrous bed and recycling a sucient amount of these fines `to the bed to maintain the concentration thereof -at-from -about 5 to about 60 weight percent to suppress begging and provide greater efficiency of contact lbetween gases and solids.

12. The process of claim 11 wherein the withdrawn ines range vin size from about 1/5 to about 1A of the average `mean particle size of the total fluidized solids particles constituting the bed.

13. The process of -claim 11 wherein the withdrawn -iines have a particle size distribution ranging from about 4 to about 400 mesh and the average mean particle size ranges between about 35 and about 100 mesh;

14. In a reaction stage of a process wherein ferrous oxides solids particles are suspended as a fluidized bed lbogging and to provide greater efficiency of contact between gases and solids.

15. The process of claim 14 wherein the said reducing gas consists essentially of hydrogen, carbon monoxide,

and nitrogen, and the average mean particle size within the bed ranges from about 48 to about 65 mesh.

References Cited by the Examiner l UNITED STATES PATENTS 2,711,368 6/1955 Lewis 75-26 2,766,102 10/1956 Lewis et alf 75-9 2,848,316 8/1958 Davis et al 75-26 2,947,620 8/1960 VJhitehouse et al. 75-26 3,092,490 6/1963 Ednie v 75-26 3,154,405 10/1964 Engle et al. 75-26 DAVID L. RECK, Primary Examiner.

BENAMIN HENKIN. Examiner. 

1. IN A PROCESS WHEREIN IRON OXIDES SOLIDS PARTICLES THE AVERGE MEAN PARTICLE SIZE OF WHICH RANGES BETWEEN ABOUT 35 AND ABOUT 100 MESH ARE FLUIDIZED IN A BED BY CONTACT OF THE PARTICLES WITH UPWARDLY FLOWING GASES AND REDUCED, THE IMPROVEMENT COMPRISING CONTROLLING THE PARTICLE SIZE DISTRIBUTION AND CONCENTRATION OF FINES SOLIDS PARTICLES BY WITHDRAWING FROM THE BED FINES RANGING IN PARTICLE SIZE FROM ABOUT 1/3 TO 1/10 THE AVERAGE MEAN PARTICLE SIZE OF THE TOTAL SOLIDS CONSTITUTING THE BED AND RECYCLING A SUFFICIENT AMOUNT OF THESE FINES TO THE BED TO MAINTAIN THE CONCENTRATION THEREOF WITHIN THE BED AT FROM ABOUT 5-60 WEIGHT PERCENT TO PROVIDE GREATER EFFICIENCY OF CONTACT BETWEEN GASES AND SOLIDS. 